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Paul.  The chassis and mechanicals look in remarkable condition to me. Somebody's definitely been there before for some resto work just by the new nyloc nuts that are visible.   Is there any way

The Postman delivered 4m of carpet today. It's a sort of poo brown although the correct colour is Autumn Leaf... Why on earth are you buying the carpet now I hear you cry, you won't need it

Funny. Steve from SJ Sportscars called me one morning about a large order, but he didn't announce himself. I run a business and often get folks trying to sell stuff, like photocopiers, water cool

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The seat foams can be repaired, but yours look pretty good. Any imperfections can be dealt with before the covers are put back so they are firm and the covers sit correctly. 
I would ditch the single headlight motor. It never worked very well. Much easier to upgrade the harness to twin and make the two motor system.

Progress in finding parts is amazing. It took me years to source stuff! Spend is also pretty good considering you have nearly all the parts, I didn’t think you would find them so easily! 
The body look like its going to take serious effort and man hours!

S and j make a bulkhead panel you could use to repair.

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I don't remember those bolt holes on the front of the pedal box, but looking back at mine the S3 version isn't far different.

328929515_PedalBoxandPlenum.thumb.jpg.19f6e1f23325ed21491e04dae59dd951.jpg

Good to assist with rare parts for this car and not so slowly see it coming together.

At this rate you'll have it on t'road in April....

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2 hours ago, jonroberts said:

So what did you do AFTER lunch then Paul ?

Put my feet up in front of the log burner. Work is very overrated and being semi-retired is much more appealing :) I plan on fully retiring at the end of June so I can then work on this 5 days/week.

58 minutes ago, Lotusfab said:

The seat foams can be repaired, but yours look pretty good. Any imperfections can be dealt with before the covers are put back so they are firm and the covers sit correctly. 
I would ditch the single headlight motor. It never worked very well. Much easier to upgrade the harness to twin and make the two motor system.

Progress in finding parts is amazing. It took me years to source stuff! Spend is also pretty good considering you have nearly all the parts, I didn’t think you would find them so easily! 
The body look like its going to take serious effort and man hours!

S and j make a bulkhead panel you could use to repair.

No I'm going to keep the single motor as that's how it left the factory and I've never had any issues with my white car. I know some people say you can't raise the headlights above 100mph but realistically how often is that problem?

@Matt-watts has offered to lend me a pair of external moulds for the front. I thought it was a daft idea to start with but the more he explained it, the more it made sense. If I just buy repair sections from SJ (which I could do at £300 +VAT) I will have to cut and trim them to fit but it will be difficult to get the shape exactly right. However, using an external mould I can then fit it to the outside of the body and repair it from the inside using gel and matting. Once it's dry and the mould is removed the shape will be exactly how it should be and I won't even have to think about it, so it makes sense and saves a ton of money too :) 

I have a spare roof section which came with the car and I need to deal with the 80s sunroof, so I'll either ask Matt if I can borrow his external roof mould or make one from the panel I have. Then to repair the sunroof you stick the external mould on and turn it upside down and lay it on an old mattress and fill it in from the inside with gel and matt.

41 minutes ago, Fridge said:

I don't remember those bolt holes on the front of the pedal box, but looking back at mine the S3 version isn't far different.

Good to assist with rare parts for this car and not so slowly see it coming together.

At this rate you'll have it on t'road in April....

The pedal box is close enough to be able to correct anything that's not quite right and fortunately, nobody will ever see it :) I don't think there's too much work to do to it... famous last words...

Edited by Paul Coleman
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Lotus Esprit [meaning] a 1:1 scale Airfix kit with a propensity to catch fire

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7 minutes ago, Paul Coleman said:

Put my feet up in front of the log burner. Work is very overrated and being semi-retired is much more appealing :) I plan on fully retiring at the end of June so I can then work on this 5 days/week.

No I'm going to keep the single motor as that's how it left the factory and I've never had any issues with my white car. I know some people say you can't raise the headlights above 100mph but realistically how often is that problem?

Matt has offered to lend me a pair of external moulds for the front. I thought it was a daft idea to start with but the more he explained it, the more it made sense. If I just but to repair sections from SJ (which I could do at 3300 +VAT) I will have to cut and trim them to fit but it will be difficult to get the shape exactly right. However, using an external mould I can then fit it to the outside of the body and repair it from the inside using gel and matting. Once it's dry and the mould is removed the shape will be exactly how it should be and I won't even have to think about it, so it makes sense and saves a ton of money too :) 

I have a spare roof section which came with the car and I need to deal with the 80s sunroof, so I'll either ask Matt if I can borrow his external roof mould or make one from the panel I have. Then to repair the sunroof you stick the external mould on and turn it upside down and lay it on an old mattress and fill it in from the inside with gel and matt.

The pedal box is close enough to be able to correct anything that's not quite right and fortunately, nobody will ever see it :) I don't think there's too much work to do to it... famous last words...

Pedal box does have the two set bolts on the front. Here is a photo of mine when I first pulled it :

 

IMG_1419.jpg

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1 minute ago, jonroberts said:

Pedal box does have the two set bolts on the front. Here is a photo of mine when I first pulled it :

Shame that picture doesn't fully show the arm which goes to the cable...

Edited by Paul Coleman

Lotus Esprit [meaning] a 1:1 scale Airfix kit with a propensity to catch fire

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3 hours ago, Paul Coleman said:

Not a massive amount of progress yesterday and today as it's too cold in my garage!
I stripped both the seats yesterday and was pleasantly surprised to find that the seat foams are all good. That's a relief as the foams would be difficult to source...
https://i.ibb.co/q5kjsWB/100-1482.jpg

Then I had a look at the brake servo and master cylinder. They're both in a bad way but the master cylinder is the worst of the two. It's very rusty and seized solid...
https://i.ibb.co/ykJw5qd/100-1485.jpg
https://i.ibb.co/HCF8CDH/100-1486.jpg
https://i.ibb.co/VNWysdc/100-1487.jpg

The servo is a little better...
https://i.ibb.co/XSHXtmv/100-1488.jpg
https://i.ibb.co/SVVHsHV/100-1489.jpg
https://i.ibb.co/r7KyJKc/100-1490.jpg

I had the master cylinder of my white car re-sleeved in stainless steel by www.pastparts.co.uk and they did a great job so I think I'm going to send them the master cylinder and servo and let them see what they can do with it. That should chew through the best part of £450. I might rebuild the brakes myself or again send them those as well. 

A couple of missing bits turned up today, namely a pedal box and a windscreen wiper motor and mechanism...
https://i.ibb.co/ZcjMN1R/100-1470.jpg
https://i.ibb.co/MM2JFfH/100-1471.jpg
https://i.ibb.co/X5jwwbD/100-1472.jpg
https://i.ibb.co/chWHQB4/100-1473.jpg
https://i.ibb.co/HpgdDdr/100-1474.jpg

the pedal box is actually out of an S3 but it's only the accelerator arm where the cable attaches that's different. So I will need to fabricate a new arm at some point but that's a long way off being a priority!

Then it was onto ignition locks/switches. this car came without a key and to get a key cut for it (without any numbers on the barrel) was going to be awkward. But I had the ignition lock from my white car which is a very early car and they had a different electrical switch which is long obsolete. So, after a bit of hunting I found it in the garage loft and low and behold it still had the original key in it and the mechanism works fine. So I drilled out the pin the holds the barrel in the lock and swapped it over. So now I have a working lock with a key and it didn't cost me anything - every little helps ;)

The early locks (the one on the right) have a different electrical switch...
https://i.ibb.co/vxLP3fX/100-1478.jpg
https://i.ibb.co/Qmmkd3b/100-1483.jpg

But never mind as I have robbed my old lock of its barrel and I now have a working later style lock that I can actually get a switch for from SJ Sportscars, so I'm very happy about that. Again, small victories...
https://i.ibb.co/HFD2jPh/100-1481.jpg

So my wanted list is growing ever shorter now and I've nearly found everything that's missing. There are only a few more items to find and I should be good to go. I just need to source...
1. The single headlamp lift motor mechanism (I've found the motor)
2. A single bonnet catch like this... https://ibb.co/dpyVwLk

I don't think it's worth trying to find an upright radiator that I can send to SJ to have rebuilt when I can just buy an alloy one and be done with it. Even if the alloy one is no better I'm assuming it won't be any worse.

The spend so far is £16,813.00

I have this that is surplus to requirements - looks to be in good shape - any good for you ? 

radiator.jpg

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19 minutes ago, Djs44 said:

I have this that is surplus to requirements - looks to be in good shape - any good for you ? 

Ooooohhhh could be. Do you have a picture of the other side please? There were 2 different vertically mounted non-AC versions of the radiator. The way to tell is whether your car has pipe #13 or #14 shown here...

https://www.rdent.com/manuals/esprit/cooling_system/ka.htm

The one I need goes with pipe #13 that has the small stub for the heater.

Thanks, Paul.

Edited by Paul Coleman

Lotus Esprit [meaning] a 1:1 scale Airfix kit with a propensity to catch fire

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18 minutes ago, Paul Coleman said:

Ooooohhhh could be. Do you have a picture of the other side please? There were 2 different vertically mounted non-AC versions of the radiator. The way to tell is whether your car has pipe #13 or #14 shown here...

https://www.rdent.com/manuals/esprit/cooling_system/ka.htm

The one I need goes with pipe #13 that has the small stub for the heater.

Thanks, Paul.

Paul 

Try these 

rad 1.jpg

rad 2.jpg

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I've better photos of my pedal box, but can no longer upload them here. I'll email you them.

Bish, bash, bosh.

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Dimensions - last time I pop out the garage through the snow tonight :)

rut is very light , looks like it may have been restored ?

rad 3.jpg

rad 4.jpg

That pedal box look lovely . I've painted mine with por 15 but i struggle with that paint to get a nice finish . 

Rut ?  rust 

 

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I had my pedal box and heater box powder coated. As well as the dash bar, bonnet release and supports. They came up great.

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7 hours ago, jonroberts said:

Any help ?

Yes, thanks. Should be easy enough to make, looks like 3mm or 4mm thick. I will have to assume 'The Lotus Position' and measure my white car.

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Lotus Esprit [meaning] a 1:1 scale Airfix kit with a propensity to catch fire

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7 hours ago, Lotusfab said:

You could use the Turbo pedal box as it came. Some of the Turbo design is an improvement on the S1.

I don't know how the throttle cable attaches to that one?

The UPS man trudged through the snow today to bring me a few more missing bits for the project.

Here we have a single headlamp lift motor and the plate for the microswitches although one of them needs changing for the 4 pin version - which is now obsolete but I just happen to have one...
https://i.ibb.co/724xzqY/100-1493.jpg

Then I also have a pair of filler necks and right angled pipes to connect to the tanks...
https://i.ibb.co/zW356fg/100-1492.jpg

The person I bought them off also had a pair of early rear calipers so I bought those as well just in case mine are toast. The early ones are square in shape around the piston area whereas the later ones are round...
https://i.ibb.co/52SYMLT/100-1491.jpg
 

The list of missing items is growing ever shorter...

Missing items when bought Current Status
Rear bumper Found (free)
Front bumper Already had one
Binnacle Already had one
Rear tailgate glass Already had one
Rear light surround Found (free)
Number plate surround Found (free)
Rear lights Already had a pair
Complete pedal box Found
Complete heater Possibly found
Heater plenum Possibly found
Single head lamp lift motor Found
Headlamp motor mechanism Not found
Sun visors Possibly found
Fuel filler necks Found
Steering column SJ (to buy)
Brown steering wheel Found
Crash pad for steering wheel Found
Boss for steering wheel Found
Gear knob Possibly found
Windscreen SJ (to buy)
Fuel filler caps SJ (to buy)
Rear valance Have a mould so will make one
Front valance Have a mould so will make one
Radiator Possibly found
Both sills SJ (to buy)
Fuel sender Not found
Windscreen wiper motor Found
Windscreen wiper mechanism Found
Bonnet catch Not found
2 front+ 2 rear Wolfrace wheels Found
Front Wolfrace wheel for spare Possibly found

 

 

Edited by Paul Coleman
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The DHL man came today with another parcel for this project. So I now have an original brown leather steering wheel, boss and crash pad. I'm pretty sure my car would have had a brown wheel rather than a black one as the interior was brown marcasite not black. So it makes logical sense that brown goes with brown and black with black. Jon Roberts car (which is the next chassis number) has a brown wheel and is identical to this one. There were 2 sizes of steering wheel... the early cars had a smaller diameter wheel where the edges of the crash pad touch the leather, like my white cars has...
https://i.ibb.co/jbsPH2r/IMG-3466.jpg

But this car would have had the larger wheel where there's a gap between the ends of the crash pad and the leather. So I'm happy that this is the correct wheel for my car...
https://i.ibb.co/ssCYzk1/100-1494.jpg
https://i.ibb.co/r4vg9wn/100-1495.jpg

I can't help thinking how ironic it would be if some of these bits that I'm buying originally came off this car!

The steering wheel and the road wheels have to be correct in my humble opinion because to me, they are some of the main defining characteristics of the S1 cars. I know the steering wheel was used on the S2 but if I'm restoring it then I feel the need to try and put it back to how it would have left the factory.

It's a shame I don't have a steering column to bolt it to hahaha But that's available via SJ Sportscars so a minor detail :)

Total spend so far: £16,885.00

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8 hours ago, Paul Coleman said:

The DHL man came today with another parcel for this project. So I now have an original brown leather steering wheel, boss and crash pad. I'm pretty sure my car would have had a brown wheel rather than a black one as the interior was brown marcasite not black. So it makes logical sense that brown goes with brown and black with black. Jon Roberts car (which is the next chassis number) has a brown wheel and is identical to this one. There were 2 sizes of steering wheel... the early cars had a smaller diameter wheel where the edges of the crash pad touch the leather, like my white cars has...
https://i.ibb.co/jbsPH2r/IMG-3466.jpg

But this car would have had the larger wheel where there's a gap between the ends of the crash pad and the leather. So I'm happy that this is the correct wheel for my car...
https://i.ibb.co/ssCYzk1/100-1494.jpg
https://i.ibb.co/r4vg9wn/100-1495.jpg

I can't help thinking how ironic it would be if some of these bits that I'm buying originally came off this car!

The steering wheel and the road wheels have to be correct in my humble opinion because to me, they are some of the main defining characteristics of the S1 cars. I know the steering wheel was used on the S2 but if I'm restoring it then I feel the need to try and put it back to how it would have left the factory.

It's a shame I don't have a steering column to bolt it to hahaha But that's available via SJ Sportscars so a minor detail :)

Total spend so far: £16,885.00

Does that include the initial purchase price ?

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47 minutes ago, Djs44 said:

Does that include the initial purchase price ?

Yes it does (£13k)

29 minutes ago, yeller77 said:

I do wish you'd stop there, Paul. Any further and I'll be forced to block my wife from this thread!

Hahaha sorry :)

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Lotus Esprit [meaning] a 1:1 scale Airfix kit with a propensity to catch fire

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Ok the S2 sender has a Value of 254 ohms when empty and 18 ohms when in the full position. Top of float to base of sender distance is 14cm when empty and 2cm when full. 

 

Its not perfect as it shows a small amount of fuel when empty but its fine if you're aware of that. 

 

 

fuel sender 2.jpg

fuel sender 3.jpg

Edited by omegaman
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